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By D. J. Tooker

For the next few minutes, I will be discussing a product and category that many people laughed at for years. The product is cat box filiers or commonly referred to by the brand name KITTY LITTER. This product was introduced in 1947 by Ed Lowe using the name KITTY LITTER. From 1947 to 1964 the product was sold mainly through pet shops. Starting in 1964, the grocery trade began to carry cat litters. From that point, the cate gory began a solid growth trend. Particularly in the '7O's, cat litter has experienced the same kind of explosive growth that has characterized the entire pet market. For example, in the twelve months ending 9/21/79, cat litter unit volume grew by 15% versus the previous twelve months. The basis for this explosive growth is easy to comprehend. The cat population itself is rapidly expanding, reflecting the changing life- styles of Americans. As famiiies grow smaller, there is room for a pet. As apartment and con dominim living shrinks living space, a cat fills the human need for animal companionship more efficiently. Table I illustrates current cat litter market factors and projects major trends into the future to conclude that the cat litter market will equal $205MM in 1985. With this dynamic growth defined, it was imperative that a company such as Lowe's that was totally devoted to the commodity-priced products, evaluate the opportunities for added- value product differentiation. This process was started approximately four years ago with a search for new cat litter products and other new product opportunities.

Jan 1, 1980

By H. G. Kok

The concept of mobile crushers is not new. Since their introduction about twenty-five years ago, mobile crushers have continued to gain widespread attention. Mobile crushers reduce minerals in the open pit mine to sizes which can be transported by belt conveyors thereby reducing or eliminating the need for truck haulage. Truck haulage is costly, often representing as much as 50% of the total mining cost. More than 80% of the cost of truck haulage is for fuel and lubricants, tire replacements, and operators' wages, and it can be anticipated that the cost of these items will continue to increase at a steady pace. Compared to truck haulage, transportation by belt conveyor is more energy-efficient, less labor-intensive, and less subject to inflation. Therefore, mobile crushers, used in conjunction with belt conveyor systems, offer one of the most effective available methods of reducing energy consumption and mining costs,

Jan 1, 1980

By W. J. Douglas

The mine manager in today's environment is faced with a wide variety of problems and challenges which must be addressed if efficient and profitable operations are to be achieved. Expansion of operations has, in many instances, resulted in inexperienced work crews, face supervisors, and superintendents. The complexities of a mining system preclude rapid movement through the learning curve for moat personnel. The management of production suffers both from this inexperience and the lack of standard procedures and methods for planning, schedul ing and analyzing production systems. The lack of visibility of information, as well as of the operations themselves, due to their remoteness, adds to the problem of production management.

Jan 1, 1980

By David B. Cook, James R. Bieke

I. INTRODUCTION Lawyers are a cautious breed; and it might be expected that a paper concerning a broad and complex area of legal regulation, prepared by lawyers for presentation to a predominantly non-legal audience, would commence with several caveats. Ours are the following: First, we have written a broad (and, in some instances, simplified) overview of the regulatory system and of some of the more important requirements generally applicable to uranium mine and mill wastes in the United States. Our paper is not a legal opinion setting forth all of the governmental requirements that would have to be met by any particular mine or mill. Similarly, we do not imply that the requirements we mention are necessarily applicable to each and every mine and mill in the country; depending on the facts, some of the requirements may be inapplicable or avoidable through exemption or variance proceedings. Compliance decisions and strategies for particular facilities must be considered on a site-specific basis. Second, we have undertaken merely to describe the regulatory framework and some of the generally "applicable" requirements which have been promulgated and proposed by administrative agencies. We express no opinion on whether, under the U.S. Constitution and statutes, the existing and proposed agency regulations are valid in general or as applied to any particular mining or milling operation. There are, of course, procedures for judicial review of agency action; and newly promulgated environmental regulations have frequently been challenged, with varying degrees of success, before the courts. For us even to begin to consider such issues would expand an already forbiddingly long paper to totally unmanageable proportions. Third, in light of the subject of this Conference we have limited our paper to the legal framework and requirements applicable to uranium mine and mill "wastes" -- primarily mine overburden and waste rock and mill tailings (including waste tailings solution). We treat operating discharges (e.g., emissions from yellowcake drying) only peripherally. Fourth and finally, it is important to note that this paper, at least in so far as it concerns the specific requirements of particular regulations, will likely soon be out of date in some important respects. Despite

Jan 1, 1980

By Philip Thompson

The Bureau of Mines investigated a selective flocculation-flotation technique to remove insoluble slimes from low-grade potash ore in a continous 45-kilogram-per-hour (100-pound-per-hour) process investigation unit (PIU). This research is part of the Bureau's program to improve resource recovery from low-grade ores. Results showed that 84 percent of the insoluble slimes were removed from an ore containing 5.5 percent water-insolubles and 14 percent K20 using a Bureau-developed, cationic flocculant-glycol ester-diesel oil reagent. Subsequent potash flotation recovered 75 percent of the potash in a cleaner concentrate assaying 56 percent K20. Concentrate leaching upgraded the product to market specifications of 60 percent K2O. An economic evaluation by the Bureau suggested that the rate of return on investment, after taxes, should be about 20 percent for such an enterprise.

Jan 1, 1980

By Irvin Mayes, Maher E. Tadros

The effects of particle properties and dispersion on the filtration behavior of magnesiumhydroxide, silica, and polystyrene suspensions in aqueous media were examined. It was found that effective separation of particles can be achieved using filter media with larger pore diameters than the size of the particles. The addition of electrolytes, at concentrations lower than the critical coagulation concentration, to suspensions of polystyrene or silica resulted in an increase of the cake resistance. This result was interpreted in terms of a decrease in the effective particle size due to the increase in ionic strength. For magnesium hydroxide, an increase in the absolute value of the surface charge was associated with an increase in cake resistance and a decrease in cake compressibility. Low cake resistance values were obtained with suspensions of large particles with low surface charge and blocky morphology.

Jan 1, 1980

By G. E. Agar, W. B. Kipkie, V. K. Drylie

"This paper describes mineral processing test work on drill core samples from an ilmenite deposit in Terrebonne County just north of Montreal.Mineralogical examination showed that the intimate associa¬tion between ilmenite and hematite precluded their separation. The maximum concentrate grade was therefore limited to 22.9% Ti. Liberation of gangue from the hemo-ilmenite grains occurred around 400 µm, a size which proved to be too coarse for recovery by flotation.Other physical separation techniques, such as elec¬trodynamic, magnetic and jigging, were tried in order to take advantage of the relatively coarse liberation size. An all-flotation procedure and a combination of jigging and flotation yielded similar separations.IntroductionInco Metals Company, through its subsidiary Canico, optioned an ilmenite deposit in Terrebonne County, just north of Montreal, and conducted a drilling campaign to confirm previous geological assessments of the deposit and to provide core samples for mineralogical study. Parts of these core samples were used for mineral processing studies, which will be described in this report. The objective was to identify suitable upgrading procedures, to determine the optimum combination of concentrate grade and recovery, and to provide suitable batches of concentrate for further treatment."

Jan 1, 1980

By L. J. Vincze

The high cost of constructing mineral processing plants in remote locations warrants a close examination of the alternatives available for reducing the amount of on-site construction work. Among the alternatives are portable process plants, modular design and barge mounted plants. Each alternative has certain advantages as well as limitations depending upon specific conditions. On the basis of practical experience and engineering analysis, the paper examines the potential benefits to be realized by these techniques and summarizes the conditions required to obtain them. The potential savings indicated by such studies should encourage consideration of innovative design features for new plants located in remote areas.

Jan 1, 1980

A Kellogg type computer model of the slag fuming process is applied in reverse to derive some thermodynamic properties of components in lead blast furnace slag. At 1200¦C, the average activity coefficients calculated were 3.40 (S.D. 0.50) for ZnO referred to the pure solid; 0.657 (S.D. 0.022) for PbO referred to the pure liquid; for the ratios y 3.175 y (referred to the Feo.9450, Fe304 pure solids) 4.19 (S.D. 1.15), and for yCaS/ 1CaO (referred to the pure solids) 5.10 (S.D. 2.96). Statistical relationships were derived for these activity coefficients and ratios as functions of the composition of slag, which contained in molar percentages 1.9 - 12.6% ZnO, 19.8 - 24.9% Fe0.9450, 0.9 - 1.6% Fe304, 0.002 - 1.9% PbO, 16.1 - 18.6% CaO, 25.9 - 31.0% SiO2, 4.8 - 5.5% MnO, 9.2 - 10.3% A101.5, 1.2 - 1.4% CaS, and 5.1 - 9.6% "Mgo" (the balance).

Jan 1, 1980

By J. H. Daniel

This report, summarizing the results of two studies sponsored by the Bureau of Mines, presents information on the types of mobile machines used in surface coal mines in the United States, and the amount of noise to which miners are exposed. Data consist of a calculated value of the probability of noise overexposure caused by specific equipment. These data are extrapolated to estimate the number of overexposed operators. Bulldozers were identified as the major contributors to noise overexposure, and the report presents results of a Bureau-funded program on the feasibility of providing retrofit noise control on bulldozers.

Jan 1, 1980

By Joseph Cervik, Gerald L. Finfinger

This Bureau of Mines publication reviews underground methane drainage pro- grams being conducted in various coalbeds. Equipment used in drainage programs such as drills, underground pipelines, and methane monitoring systems is described.

Jan 1, 1980

By R. E. Stewart

"Using the concept of economic life and marginal analysis, it can be shown that proper equipment replacement timing can save a mining company many thousands of dollars. To assist management with determining the economic life of mining equipment, a new computer package has been developed. The package, called ERG (equipment replacement guide), incorporates all important economic factors related to equipment usage, such as operating costs, maintenance costs, salvage values, depreciation, volume of work, tax credits, inflation rates, ROJ, etc. The information is used in a series of equations which balance the costs of new equipment against the total cost of old equipment. The solution of the equations determines economic life and the point in time when the old equipment should be replaced. IntroductionIn an operating mine, equipment must eventually be replaced or downgraded for a variety of reasons. Fleets of haul trucks, dozers and other major pieces of equipment deteriorate over time until the mounting costs of maintenance and repair force either a major overhaul or the ir replacement by new and more efficient pieces of equipment.The question of determining the best time to replace old equipment has been approached in many different ways. Various methods, ranging from operating experience, intuition and physical necessity to sophisticated computer models have been devised to help cope with equipment replacement decisions . The best of the se will incorporate the most important economic factors related to equipment usage, such as operating and maintenance costs, salvage values, depreciation, work delivered, the cost of capital, tax credits and, of course, the effects of inflation.Economic TheoryThe fundamentals of equipment replacement theory grew out of the interaction between economics, engineering and finance. The use of annual cost comparisons and rate-of return calculations were helpful in handling situations in which assets with different finite lives were being compared. Later developments bringing together the concept of economic life and marginal analysis helped provide additional refinements to the theory. Taylorui showed that the displacement of an aging asset with a similar, but newer, asset can be justified economically when the marginal cost of keeping the asset one more year exceeds the minimum uniform annual cost equivalent of the proposed replacement."

Jan 1, 1980

By Peter C. Ashbrook

The Regional Copper-Nickel Study was initiated in large part because of fears that copper-nickel development might cause adverse effects on the environment from air pollutants such as sulfur dioxide (SOZ) emissions from a smelter, and water pollutants such as acid mine drainage. The Study comprehensively examined the potential for ad- verse effects on the environment and possible mitigation measures on both a local and regional scale by first characterizing existing air and water quality, and existing sources of pollution, and then developing hypothetical development scenarios to model potential adverse effects. This paper gives a brief overview of the Study's findings concerning air and water resources.

Jan 1, 1980

By Vishnu S. Gupta

A modular computer program APEX (AMAX Process Evaluation Executive), has been developed at AMAX Extractive R&D, Golden, Colorado to facilitate rapid simulation of steady state material and energy balances of existing and/or proposed metallurgical process flowsheets. Currently, APEX is being used for the design, analysis, and evaluation of several of AMAX?s Nickel, Molybdenumand Tungsten processes. A unique feature of APEX is that it allows specifications of flow rates and compositions for different solid size fractions in addition to aqueous organic and gaseous phases. Thus, a metallurgical process which may involve crushing, grinding, flotation, leaching, washing, solvent extraction, precitation and refining operations can be simulated in a single computer run using APEX. APEX requires two input data files. The first is a process data file which includes physical and thermodynamic properties of the various chemical components of interest. This data file is unique to the process under study and does not require changes for alterations in the process flowsheet. The second data file is specific to a simulation case and includes descriptions of the flowsheet, various feed streams and the process equipment's operating conditions. In addition to temperature, pressure and percent solids, calculated information for each stream includes weight and volumetric flow rates, chemical compositions, specific gravities and enthalpies of solid, liquid and gas phases. For each process equipment in the flowsheet, APEX prints its operating conditions and detailed information about the streams that enter and leave the unit. Models of several general unit operations are preprogrammed in APEX. Also, the modular design of APEX permits quick and easy additions of simulation models which are specific to new and/or unique process operations. To study process stability and optimization, APEX permits several cases of a flow-sheet to be run together. Three simulations of the Moa Bay Nickel process have been excluded to illustrate the ease and flexibility of using the APEX system.

Jan 1, 1980

By David A. Fawcett

"This paper presents a summary compilation of current Canadian coal research projects in the areas of exploration, mining and preparation. The compilation forms the basis for a review of present operations and technology, and of current research efforts. General research areas, requirements and priorities are suggested along with a discussion on achieving the research goals in terms of funds, facilities and staff. The current level of research funding in these areas is assessed. IntroductionCanada's coal production is expected to undergo major expansion over the next two decades in response to domestic demands on coal for electrical power generation, industrial uses and conversion to synthetic .fuels, and in response to export demands for both thermal and metallurgical coal s. Surface mining will continue to dominate, but underground mining will contribute an increasing proportion to total production.In Canada, coal research, particularly in the areas of exploration, mining and preparation (E, M & P), has been limited. Increased impetus has recently been given to this research with expansion of CANMET's activities and with the establishment of the Coal Mining Research Centre (CMRC). University researchers are branching into coal research; strata mechanics and preparation are popular in mining-related fields.With the increase in number of organizations and individuals involved in coal research, a means of keeping abreast of the ongoing work is necessary. An annual summary of the status of and developments in current research assists in providing this information. The CMRC prepared such a summary for Canadian coal E, M & P research in 1979 and it received favourable response, justifying the effort. A 1980compilation has been prepared and pro vides the basis for this paper; it is presented with a brief discussion on background, format and content.The compilation forms a basis for an examination of the current status of Canadian technology in E, M & P and of the ongoing research in each area. General research requirements are reviewed and programs and tasks are suggested, followed by a discussion of research goals in term s of priorities and achievement. An assessment is made of the level of research funding in Canada, with comparisons drawn from the United States, the United Kingdom and Australia."

Jan 1, 1980

By A. N. Khayyat, R. G. Temple, R. Skelton

The fluid energy mill has been in use since the 1930's when an early patent was granted to N.H. Andrews in the USA. The microniser design has been basically unaltered since that date and current designs such as the Airfilco "Micronizer" have been progressively developed from results based on wide experience. The authors have been engaged in a research programme to establish optimum design and operational parameters for the Micronizer so as to provide a more quantitative basis for scale-up prediction of results. An introductory section will first trace the development of fluid energy milling including reference to other designs which have developed alongside the micronizer (especially the “Jet-o-miser"). With regard to design features the number of fluid injection nozzles and their size was investigated to establish the optimum range. Injection angle and, the consequent diameter of the internal "tangential circle" was carefully studied to determine the effect of this parameter on product size. The research was carried out using fine limestone as the test material with air as the grinding medium. Feed size fractions of 0-120µm, 0-250µm, 0-500µm, and 300-600µm were milled and product size analyses were carried out using the Coulter Counter technique.

Jan 1, 1980

By Joe D. Mitzel

The Indian Head fine has been in existence since 1922. For over 56 years there have been North Dakota people mining coal at this same location. The area affected will fit inside a circle 5 km in diameter, and the coal is lignite. The seam thickness has varied from 2.4 m to 3.65m, and the overburden from 6 m to 30 m in depth. me Lignite coal which is being mined at the Indian Head Mine is from 15.8 x l0 6 to 16.7 x 10 6 J per kg; it has a moisture content of 33 to 38%; an ash content of 5 to 10%; and a sulfur content of from 0.5 to 0.7%. The moisture content and the fact that we crush the coal co a top size of 14 cm x 0, are two of the characteristics or the product which cause it to freeze and remain inside of the railroad cars on the slope sheets. The market for the coal initially was almost entirely local coal sales. That is, coal was sold to people in the area who used the lignite to heat their homes, stores, offices, schools, and churches. Back in the early 1920's, there were no stoker-fed boilers, or pulverized fuel boilers, as we have in today?s marketplace. Basically, all of the coal was sold as lump coal, pieces about 30 to 35 cm square, to be used in furnaces: and nut coal with a top size of about 7.5 cm to 10 cm to be used in the old kitchen cookstove. All of the coal fines, less than 5 cm, were screened out and layed onto a pile. There was no market for the smaller sizes of the lignite coal. It has been our experience that when the coal is in lumps or chunks larger than 7.5 cm to 10 cm, there is a very slight possibility of freezing. That is the chunks themselves freeze, but by their nature, they do not cling to one another or form large masses of frozen material which are difficult to remove from the slope sheers of the railroad cars.

Jan 1, 1980

By R. C. Runvick

Gypsum resources are significant in the midwestern United States, with specific deposits varying in "place value" relative to the major markets served. Underground and surface mining operations produce gypsum from sedimentary rocks ranging in age from Silurian through. Jurassic. Although reserves tend to be limited at individual operating properties, potential resources are vast and future development will hinge principally on market growth and changing economic conditions. Most critical of the variables affecting the industry in both the short and long term will be the availability, type and cost of energy and both processing and distribution.

Jan 1, 1980

By Jean-Guy L. Gauthier

"With the Ontario Ministry of the Environment stipulating that the cumulative concentration of copper, lead, zinc and nickel in mine mill effluent must be no greater than 1.0 milligram per litre, it has become necessary for the mining industry of find some form of treatment for the removal of heavy metals from effluent waters.To comply with these guidelines, it became necessary for Mattabi Mines Ltd., which is situated 50 miles Northeast of Ignace in Northwestern Ontario, to develop a compact, cost effective and technically sound treatment process to remove heavy metals from their tailings overflow. A design committee consisting of mine metallurgists, environmental engineers, a Dutch research and development team and the equipment supplier engineering staff was set up to accomplish this.Using some new and innovative wastewater treatment equipment, the guidelines established by the Ontario Ministry of the Environment can now be met. The sludge produced from the precipitated heavy metals is sent directly to the concentrator, thus eliminating the danger of re-dissolution of the metals in a landfill site, while recovering some of the valuable metals that would otherwise be wasted in a sludge landfill."

Jan 1, 1980

By Y. C. Kim

This paper reviews the past 18 months of geostatistical work in a coal deposit performed jointly by the University of Arizona and the Homer City Owners. The objective of the study was to better predict the in-seam sulfur values of the deposit for the purpose of future emission control. Based on initially available 112 DDH information, variogram models were developed for Sulfur, Ash and Thickness for the entire deposit. The deposit was then kriged using 333 m x 333 m (1000 ft x 1000 ft) panel size. The estimation variance information obtainable from geostatistics was next utilized to improve the development drilling activities that were underway. The results of this effort are presented in this paper. In addition, this paper describes (1) the reasons for preferring kriging over the conventional isopachs, (2) the results of empirical validation of the kriged estimates using 19 additional DDH information, and (3) up-to-date experience on the use of conditional simulation of the same deposit for the future emission control strategy development.

Jan 1, 1980